Shaped structures of graphite fabrics, and the like, and deep drawn molded products therefrom

Abstract

An interwoven fabric having moveable layers of graphite, fiberglass, Kevlar, and similar materials are wrapped or conformed around shaped mold parts. These layered shape parts are subsequently impregnated with resin and cured to produce a reinforced product having a reasonably uniform fiber density. Typical shaped structures include boxes, hemispheres, ojives, etc. The process is particularly suitable for producing structures where the fabric distortion is severe at corners, angles, and so forth.

I claim: 
     
       1. A process for forming a woven, multi-layer, continuous fabric into resin-impregnated shapes, comprising: a. applying the fabric to a mold, as a continuous and uniform wrapping, the fabric including upper and bottom layers partly interwoven with an inner layer to form moveable layers with respect to each other, the interweave between an inner layer and an outer layer being about 5% of the total weave in a layer;   b. continuing applying the fabric to the mold and moving the layers with respect to each other to conform the fabric uniformly with the mold and any irregularities thereon, until the fabric has been built up to a final shape;   c. impregnating the shaped fabric with a thermosetting resin; and,   d. curing the resin to form the cured, resin-impregnated fabric shape.   
     
     
       2. The process of claim 1, in which the fabric wrapped shape is stored prior to impregnation and curing. 
     
     
       3. The process of claim 1, in which the fabric layers are selected from the class consisting of fiberglass, graphite and Kevlar. 
     
     
       4. The process of claim 1, in which the fabric comprises three layers. 
     
     
       5. A woven, continuous, multi-layered, molded fabric shape impregnated with a thermosetting resin, the fabric having upper and bottom layers interwoven with an inner layer, thereby comprising three moveable layers with respect to each other, the interweave between an inner layer and the upper and bottom layers being about 5% of the total weave in a layer; the fabric being applied to a mold while moving the fabric layers with espect to each other to conform the fabric uniformly with respect to the mold and any irregularities thereon, and continuing application of the fabric to the mold until the fabric has been built up to a final shape.   
     
     
       6. The molded fabric shape of claim 5, in which the resin has been cured. 
     
     
       7. The molded fabric shape of claim 6, in which the fabric wrapped shape is stored prior to curing. 
     
     
       8. The molded fabric shape of claim 5, in which the upper and bottom layers are woven as a pick and plain weave. 
     
     
       9. The molded fabric shape of claim 5, in which the fabric layers are selected from the class consisting of fiberglass, graphite and Kevlar.